System and method for reclaiming waste carpet materials

ABSTRACT

The present invention relates generally to the reclaiming of carpet waste material. More particularly, the invention relates to a method and system for reclaiming carpet components such as yarn, tufting primary, binder, and secondary backing from post industrial and post consumer carpet waste in a substantially continuous flow process.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. patentapplication Ser. No. 13/699,197, filed Nov. 5, 2012, which claims thebenefit of priority to U.S. Provisional Patent Application Ser. No.61/555,241, filed on Nov. 3, 2011, the entire disclosures of which areincorporated by reference herein for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to the reclamation of carpetwaste material. More particularly, the invention relates to a method andsystem for reclaiming carpet components such as yarn, tufting primaryand secondary backing for recycling.

BACKGROUND OF THE INVENTION

Waste material inflow into resource limited landfills is strained by thevoluminous amount of post consumer carpet waste produced by carpetdistributors and carpet installation contractors and post industrialcarpet waste produced by carpet manufacturers. Post industrial carpetwaste can include, for example, commercial, industrial and residentialcarpet waste; manufacturing remnants; quality control failures, and thelike. Post consumer carpet waste can be, for example, used carpet, e.g.,carpet removed from a home, apartment complex, or a commercialinstallation, or unused carpet, e.g., residual carpet left from aninstallation or manufacturing process. While most estimates indicatethat carpet waste constitutes only 1 to 2% of all municipal solid waste,this amount still represents a vast quantity of waste that can have asubstantial economic and environmental impact.

The carpet waste inflow into landfills is not generally environmentallybeneficial. In an effort to mitigate the amount of carpet waste that isshipped to landfills, efforts are being made to manually recycle atleast a portion of the carpet waste prior to insertion into the landfillwaste stream. Recycling carpet, however, is difficult because its majorcomponents are chemically and physically diverse.

Most carpets comprise about 20-50 percent weight face fiber, theremainder being backing materials, commonly polypropylene, and anadhesive which attaches the carpet fiber to the backing material. Theadhesive typically comprises a carboxylated styrene-butadiene (XSB)latex copolymer, and inorganic filler like calcium carbonate. Thesematerials are frequently incompatible with each other in a recyclingoperation. For example, the means used to separate and reuse a layer ofthe backing material might affect the usefulness of the pile material.Alternatively, a chemical used in the recycling process might dissolvetwo or more of the components, causing them to intermix and form a blendof the two materials having less desirable properties. The applicationof heat to melt certain materials can have the same effect. Because ofthese difficulties, to date the amount of carpet reclaimed throughrecycling operations is limited and only a minimal percentage of thetotal carpet waste may be useful in the production of green technologyproducts. Accordingly, there is a need for efficient recycling of postindustrial and post consumer carpet waste to reduce the amount of wastebeing disposed of at landfills.

In light of the various shortcomings of prior attempts to effectivelyrecycle spent carpeting, a need is recognized for a system and methodcapable of effectively and efficiently separating the constituentmaterials of used carpeting, so that those materials can be effectivelyrecycled into new product with a minimum of discarded material and aminimum need to add virgin material to reduce contamination levels.

A further need is recognized for a scheme that makes effective andefficient use of the reclaimed materials in new carpeting. The need forvirgin material should be kept to a minimum, in order to decrease costsand increase the amount of old material that is converted into newcarpeting. In addition, such broad-based recycling methods can alsopotentially help to comport with National Sanitation Foundation (NSF)140/2007 recommendations, which encourage carpet industries to developsustainable carpet manufacturing and recycling programs for social,economic, and environmental benefits.

SUMMARY

The present system and method is capable of reclaiming heterogeneouscarpet waste materials from streams of post industrial and/or postconsumer carpet waste at higher levels of efficiency and lower levels ofcontamination than have previously been accomplished. To accomplishthis, the invention provides a method and system for reclaiming carpetcomponents such as yarn, tufting primary, binder, and secondary backingin a substantially continuous flow process.

As discussed above, carpet materials typically have several layers ofdifferent materials. The simplest types of carpet might have fibrouspile material (nylon, for example) fused directly to a thermoplasticprimary backing material. However, there can also be a secondary binderor substrate layer, a reinforcing web material through which the pile isattached, or a separate glue material that is used to anchor the pile tothe backing. The present invention is operative to separate theconstituent materials, so that the separate types of materials can berecycled.

Additional embodiments of the invention will be set forth, in part, inthe detailed description, figures, and claims which follow, and in partwill be derived from the detailed description, or can be learned bypractice of the invention. It is to be understood that both theforegoing general description and the following detailed description areexemplary and explanatory only and are not restrictive of the inventionas disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the preferred embodiments of the inventionwill become more apparent in the detailed description in which referenceis made to the appended drawings wherein:

FIG. 1 is a block diagram illustrating the steps performed in theseparation stage of a carpet waste reclamation system.

FIG. 2 is a schematic representation of an exemplary method and systemfor separating the constituent materials of a carpet, showing a firstshear subsystem and a second, downstream, shear subsystem that areconfigured for separating face materials and secondary backing materialsfrom a primary backing material of the carpet. In the illustratedexample, the respective first and a second shear subsystems comprise apair of spaced and opposed rotating shearers.

FIG. 3 is a schematic representation of an exemplary method and systemfor separating the constituent materials of a carpet, showing a firstshear subsystem and a second, downstream, shear subsystem that areconfigured for separating face materials and secondary backing materialsfrom a primary backing material of the carpet. In this example, each ofthe respective first and second shear subsystems comprises a pair ofrotating shearers positioned adjacent to each other. Further, the secondshear subsystem is positioned opposed to and downstream of the firstshear subsystem.

FIG. 4 is a schematic representation of an exemplary method and systemfor separating the constituent materials of a carpet, showing a firstshear subsystem and a second, downstream, shear subsystem that areconfigured for separating face materials and secondary backing materialsfrom a primary backing material of the carpet. In this example, therespective first and a second shear subsystems comprise a two pairs ofspaced and opposed rotating belt-type shearers.

FIGS. 5-9 illustrate a schematic representation of an exemplary methodand system for separating the constituent materials of a carpet, showinga first shear subsystem and a second, downstream, shear subsystem thatare configured for separating face materials and secondary backingmaterials from a primary backing material of the carpet. In thisexample, each of the respective first and second shear subsystemscomprises a pair of spaced rotating shearers. Further, the second shearsubsystem is positioned opposed to and downstream of the first shearsubsystem. In this example, it is contemplated that the backing materialand the fiber material will be separated from the primary backing bysequential abrasion steps.

FIG. 10 is a schematic representation of an exemplary method and systemfor separating the constituent materials of a carpet, showing a firstshear subsystem and a second, spaced, shear subsystem that areconfigured for separating face materials and/or secondary backingmaterials from a primary backing material of the carpet. In thisexample, the respective first and second shear subsystems comprise apair of spaced rotating shearers and the carpet is repeatedly urgedbi-axially along a machine direction under the respective first andsecond shear subsystems until a desired degree of material is removedfrom the carpet.

FIG. 11 is a schematic representation of exemplary methods and systemsfor sensing the tuft height of the fiber material, the density of thecarpet, and the backing material height.

DETAILED DESCRIPTION

The present invention may be understood more readily by reference to thefollowing detailed description, examples, drawings, and claims, andtheir previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this invention is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,as such can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to a “waste stream” caninclude two or more such waste streams unless the context indicatesotherwise.

Ranges may be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance may or may not occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

Without the use of such exclusive terminology, the term “comprising” inthe claims shall allow for the inclusion of any additionalelement-irrespective of whether a given number of elements areenumerated in the claim, or the addition of a feature could be regardedas transforming the nature of an element set forth in the claims. Exceptas specifically defined herein, all technical and scientific terms usedherein are to be given as broad a commonly understood meaning aspossible while maintaining claim validity.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition or article,denotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a composition or a selectedportion of a composition containing 2 parts by weight of component X and5 parts by weight component Y, X and Y are present at a weight ratio of2:5, and are present in such ratio regardless of whether additionalcomponents are contained in the composition.

A weight percent of a component, unless specifically stated to thecontrary, is based on the total weight of the formulation or compositionin which the component is included.

As used herein, and unless the context clearly indicates otherwise, theterm carpet is used to generically include broadloom carpet, carpettiles, and even area rugs. To that “broadloom carpet” means a broadloomtextile flooring product manufactured for and intended to be used inroll form. “Carpet tile” denotes a modular floor covering,conventionally in 18″×18″, 24″×24″ or 36″×36″ squares, but other sizesand shapes are also within the scope of the present invention.

The present invention may be understood more readily by reference to thefollowing detailed description of preferred embodiments of the inventionand the examples included therein and to the Figures and their previousand following description.

FIG. 1 schematically illustrates a carpet waste reclamation method andsystem 100 according to one aspect of the present invention. As shown,carpet waste 10 is provided, such as the exemplary post consumer carpetillustrated. However, it is contemplated that the carpet waste can bederived from any carpet. In one aspect, and without limitation, thecarpet waste can be a post-consumer carpet, post-consumer processed, forexample, carpet carcasses, and post-industrial, for example, selvedge,seams, and the like. It is contemplated that the carpet waste can alsocomprise manufacturing remnants, quality control failures, and the like.In a further aspect, carpet waste can comprise a carpet waste that wouldotherwise be discarded or landfilled by a consumer, distributor,retailer, installer, and the like.

The carpet waste 10 can be derived from any desired carpet structure,including without limitation, tufted carpet, needle-punched carpet, andeven hand woven carpet. In another aspect, the system and methoddescribed herein can be used in connection with broadloom carpets,carpet tiles, and even area rugs, so long as the carpet structurecomprises at least one inorganic component desired for reclamation. Inone aspect, a typical conventional carpet waste structure comprisesfiber bundles, a primary backing material, an optional pre-coat layer,an adhesive backing material, an optional reinforcing layer, and anoptional secondary backing material. In the present invention, it iscontemplated that the carpet waste will be deconstructed or reclaimedinto three primary waste streams, a face material or face fiber wastestream, a backing material having some degree of face fiber wastestream, and a primary backing waste stream,

In one aspect, the carpet waste can comprise an inorganic fillercomponent. The inorganic filler component can comprise, inter alia,calcium carbonate, calcium sulfate, calcium silicate, magnesiumcarbonate, magnesium oxide, magnesium hydroxide aluminum trihydrate,alumina, hydrated alumina, aluminum silicate, barium sulfate, barite,flyash, glass cullet, glass fiber and powder, metal powder, clay, silicaor glass, fumed silica, talc, carbon black or graphite, fly ash, cementdust, feldspar, nepheline, zinc oxide, titanium dioxide, titanates,glass microspheres, chalk, and mixtures thereof. Among these, preferredfillers comprise calcium carbonate, barium sulfate, talc, silica/glass,alumina, and titanium dioxide, and mixtures thereof. More preferablefillers comprise calcium carbonate.

In another aspect, the filler can be ignition resistant. Exemplaryignition resistant fillers can comprise antimony oxide,decabromobiphenyl oxide, alumina trihydrate, magnesium hydroxide,borates, and halogenated compounds. Of these ignition resistant fillers,those that comprise alumina trihydrate and magnesium hydroxide arepreferred.

Carpet waste can be provided to the system 100 in the form of bales. Asone will appreciate, baled carpet waste can enhance the ease of thedelivery and movement of the carpet waste. Optionally, the carpet wastecan be provided to the system 100 palletized or in a loose or otherwisenon-compacted condition. In one aspect, it is contemplated that thecarpet waste can be provided to the system 100 in a stacked condition.It is also contemplated that landfill owners and/or operators can alsoprovide incentives for stacking or baling of carpet to reduce the volumerequirement of the landfill.

Referring back to FIG. 1, once the carpet waste 10 is delivered to thesystem, the palletized carpet waste is placed in a stacked condition ona roller conveyor 15 and urged onto a lift table 20 that is configuredto urge the carpet waste 10 downstream to an air table 25. This systemis configured to accept stacked carpet waste pieces and to feed eachindividual flat piece of carpet waste downstream at a desired rate, insingle form with correct orientation. The roller conveyor can beconfigured with a conventional pressure sensing system for monitoringthe supply of delivered carpet waste and a fork truck sensing system.The lift table can be any conventional lift table or device that iscapable of separating the stacked carpet waste from the pallets andurging the individual pieces of carpet waste material downstream to theair table. As one will appreciate, the air table can be any conventionalair table or device that is capable of separating at least a portion ofthe contamination materials, such as dirt, present in post consumercarpets from the constituent carpet materials. Any separatedcontamination materials are recovered for subsequent landfillprocessing.

After the air table, the carpet waste pieces are conveyed to the infeedconveyor system 30. In one aspect, the infeed conveyor system 30 cancomprise a means for removing wrinkles from each individually feed pieceof carpet waste 10. It is contemplated that the infeed conveyor systemcan comprise, without limitation, a sequentially positioned series ofone or more of the following: slowed speed rollers or belts, crownedrollers, fluted rollers (bow and skew), driven belts, driven belts atangles, driven rollers at angles, low friction driven belts, highfriction driven belts. As one will appreciate, slowed speed rollers orbelts can be configured to progressively increase in speed as thematerial flows downstream through the infeed conveyor system, whichdynamically applies force to the individual carpet waste pieces andthereby forcefully pulls out wrinkles in a direction parallel to thedownstream machine directional flow. As one will also appreciate,sequentially positioned crowned and fluted bow and skew rollers can beconfigured to remove wrinkles in the width wise direction. Thus, it iscontemplated that the integrated infeed conveyor system can beconfigured to spread, flatten, and stretch each individual piece ofcarpet waste. In a further aspect, it is contemplated that each rollercan move relatively up or down, i.e., transverse, to the downstreammachine directional flow for compliance for thickness or wrinklepresence. In this aspect, it is contemplated that infeed conveyor systemcan also comprise a means for selectively applying desired pressure inthe up or down direction to the individual carpet waste pieces.Optionally, and without limitation, it is contemplated that the meansfor selectively applying desired pressure can be pneumatic, hydraulic,spring, weighted, and the like.

Subsequent to the infeed conveyor system 30, the flattened individualpieces of carpet waste are feed directly into the component wasteseparation system 40. In various aspects and referring to FIGS. 2-10,the component waste separation system 40 can comprise at least one of: atractor feed subsystem 50, an shear subsystem 55, a carpet waste sizesensing subsystem 60, a backing thickness sensing subsystem 65, a tuftheight and tuft density sensing subsystem 70, and a waste stream outputmonitoring subsystem 75.

In one aspect, the tractor feed subsystem 50 comprises means forselectively indexing individual flattened pieces of carpet waste throughthe component waste separation system 40. The means for selectivelyindexing individual flattened pieces of carpet waste through thecomponent waste separation system 40 is configured to nip the carpet asit is moved in the downstream machine direction to affect the desiredcontrol of the orientation and metering of the carpet waste material ata specified rate. In one aspect, the rate can be constant or can becontrolled as desired for the respective carpet waste material that ispassing therethough the component waste separation system 40.

In one exemplary aspect, the means for selectively indexing individualflattened pieces of carpet waste through the component waste separationsystem 40 can be a plurality urging elements 52, such as, for exampleand not meant to be limiting, belts or pin rollers, which are positionedto maintain the individual carpet waste materials in a desiredorientation while moving or otherwise urging the carpet waste materialthrough the shear subsystem 55. In one aspect, it is contemplated thatthe belt can be continuous or segmented across the face of the carpetwaste piece. In another aspect, it is also contemplated that the urgingelements 52 can have pins, flutes, grooves, high friction surface, gripsurface or other conventional profiles for gripping and securing thecarpet piece while urging the carpet waste material downstream.

In one aspect, it is contemplated that the plurality of urging elementscan comprise two pluralities of urging elements 52′, 52″. Asillustrated, in this embodiment, each plurality of urging elements arepositioned substantially parallel to each other and the two pluralitiesof urging elements can be positioned, at least partially, in opposing,overlapping relationship to each other. It is also contemplated thateach plurality of urging elements can also comprise a means forselectively applying desired pressure in the up or down direction, i.e.,transverse, to the downstream machine directional flow, to theindividual carpet waste pieces in order to maintain the desired nip andto prevent slippage of the individual carpet waste pieces. Optionally,and without limitation, it is contemplated that the means forselectively applying desired pressure can be pneumatic, hydraulic,spring, weighted, and the like.

As shown in FIGS. 2-9, in one aspect, the shear subsystem 55 of thecomponent waste separation system 40 can comprise a plurality of shearsubsystems 55. In one aspect, it is contemplated that a first shearsubsystem 55′ can be configured to contact the incoming carpet wastepieces to remove or otherwise separate the secondary backing materialsfrom the primary backing material of the individual flattened carpetwaste pieces. In another aspect, a second shear subsystem 55″ can beconfigured to contact the incoming carpet waste pieces to remove orotherwise separate the face fiber or face materials from the primarybacking material of the individual flattened carpet waste pieces.

In various aspects, and as shown in FIGS. 3 and 5-9, the respectivenumber of the first and second shear subsystems 55′, 55″ can beincreased as desired to provide for an overall increase in thethroughput of carpet waste pieces through the plurality of shearsubsystems 55 of the component waste separation system 40 and to allowfor stepped sequential removal of secondary backing material and facefiber/face material as the carpet waste piece is moved downstreamthrough the component waste separation system 40. It is contemplatedthat the use of such a segmented first and second shear subsystems 55′,55″ can improve nipping and carpet control by shearing swathes betweenrespective segmented urging elements 52′, 52″.

In another aspect, each of the shear subsystems can comprise at leastone of a rotating-type shearer, a belt-type shearer, and the like. Inone aspect, it is contemplated that each of, or at least one of theshear subsystems, can comprise a conventional blade shear system that isconventionally configured to remove a desired portion of the facefiber/face material as the carpet waste is continuously and linearlymoved downstream through the component waste separation system 40.

Optionally, the rotating shearer can be continuous rotating shearer or asegmented rotating shearer. In this aspect, at least a portion of eachof the respective rotating or belt-type shearers has a conventionalabrasion surface 57, which can be, for example and without limitation, aconventional grit surface that is bonded or otherwise coupled to atleast a portion of the exterior surface of the wearer, and the like. Itis also contemplated that the abrasion surface can be formed with aseries of male flutes having hardened surfaces for extended wear life.In one aspect, the rotating shearer can have a large diameter forincreased life and more surface contact.

In another aspect, at least one of the shear subsystems can alsocomprise means for selectively moving the shear subsystem and/orapplying desired pressure in the up or down direction, i.e., transverse,to the downstream machine directional flow, to the individual carpetwaste pieces in order to maintain the desired level of the abrasionsurface relative to the primary backing of the individual carpet wastepieces. Optionally, and without limitation, it is contemplated that themeans for selectively applying desired pressure can be pneumatic,hydraulic, spring, weighted, and the like.

It is contemplated that the speed of each shear subsystem can bevariably controlled to reduce fiber wrapping around the rotating shearsubsystems and to maximize the abrasion surfaces operational life. Inone aspect, the variable control of the speed of each shear subsystemcan be selectively controlled in accord with signals received from acomputer control system 80, such as, for example and without limitation,a centrally located Programmable Logic Controller, that is incommunication with the respective carpet waste size sensing subsystem60, a backing thickness sensing subsystem 65, a tuft height and tuftdensity sensing subsystem 70.

In one example, the downstream segmented shear subsystem system 55,offset from the upstream shear subsystem 55, would remove the backingmaterial or face material, not removed by the upstream shear subsystem.As shown, the segmented belts or pin rollers 52′, 52″ nip the carpetbetween each segmented shear subsystem 55. In various combinations, itis contemplated that both of the upstream and the downstream shearsubsystems that are positioned on both sides of the component wasteseparation system 40 can be rotated in the same direction or in opposingdirections relative to each other. In this aspect, an upstream shearsubsystem can be rotated in the machine direction of the component wasteseparation system 40 and the downstream shear subsystem can be rotatedin a direction opposite to the machine direction of the component wasteseparation system 40.

Referring to FIG. 2, the component waste separation system 40 isexemplary shown with a first shear subsystem 55′ and a second,downstream, shear subsystem 55″ that are configured for separating facematerials and secondary backing materials from a primary backingmaterial of the carpet. In this example, the respective first and asecond shear subsystems comprise a pair of spaced and opposed rotatingshearers having conventional shear surfaces. As one will appreciate, twopluralities of belts or pin rollers 52′, 52″ are shown are positionedsubstantially parallel to each other in at least partially opposing,overlapping relationship to each other.

Referring to FIG. 3, the component waste separation system 40 isexemplary shown with a first shear subsystem 55′ and a second,downstream, shear subsystem 55″ that are configured for separating facematerials and secondary backing materials from a primary backingmaterial of the carpet. In this example, each of the respective firstand second shear subsystems comprises a pair of rotating shearerspositioned adjacent to each other. Further, the second shear subsystemis positioned opposed to and downstream of the first shear subsystem. Asone will appreciate, two pluralities of urging elements, e.g. belts orpin rollers 52′, 52″, are shown are positioned substantially parallel toeach other in at least partially opposing, overlapping relationship toeach other.

Referring to FIG. 4, the component waste separation system 40 isexemplary shown with a first shear subsystem 55′ and a second,downstream, shear subsystem 55″ that are configured for separating facematerials and secondary backing materials from a primary backingmaterial of the carpet. In this example, the respective first and asecond shear subsystems comprise a two pairs of spaced and opposedrotating belt-type shearers. Further, the second shear subsystem ispositioned opposed to and downstream of the first shear subsystem. Asone will appreciate, two pluralities of belts or pin rollers 52′, 52″are shown are positioned substantially parallel to each other in atleast partially opposing, overlapping relationship to each other.

Referring now to FIGS. 5-9, an exemplary method and system forseparating the constituent materials of a carpet is shown. Asillustrated, a first shear subsystem 55′ and a second, downstream, shearsubsystem 55″ of the component waste separation system 40 are configuredfor separating face materials and secondary backing materials from aprimary backing material of the carpet. In this example, each of therespective first and second shear subsystems comprises a pair of spacedrotating shearers. Further, the second shear subsystem is positionedopposed to and downstream of the first shear subsystem. In this example,it is contemplated that the backing materials and the fiber materialswill be separated from the primary backing by sequential shearing orabrasion steps as the carpet waste material is passed sequentiallythrough the shear subsystems.

FIG. 10 is a schematic representation of an exemplary method and systemfor separating the constituent materials of a carpet, showing a firstshear subsystem and a second, spaced, shear subsystem that areconfigured for separating face materials and/or secondary backingmaterials from a primary backing material of the carpet. In thisexample, the respective first and second shear subsystems comprise apair of spaced rotating shearers and the carpet is repeatedly urgedbi-axially along a machine direction under the respective first andsecond shear subsystems until a desired degree of material is removedfrom the exposed face of the carpet. In one aspect, the pair of spacedrotating shearers comprises a first rotating shearer and a secondrotating shearer that is configured to rotate counter to the rotationdirection of the first rotating shearer. In one aspect, in operation,piece of carpet waste is disposed onto a conveyor surface for biaxialmovement along a machine direction past the first and second shearsubsystems. As the edge of the carpet waste piece is urged in a firstmachine direction and the carpet waste piece passes under and proximatethe first rotating shearer, the first rotating shearer is lowered intooperative contact with the exposed material of the carpet waist piece(concurrently, the second rotating shearer is raised up and away fromcontact with the carpet piece). As a middle portion, or a desiredportion, of the carpet piece passes under and proximate to the secondrotating shearer, the second rotating shearer is lowered into operativecontact with the exposed material of the carpet waist piece(concurrently, the first rotating shearer is raised up and away fromcontact with the carpet piece).

Subsequent to the pass of the carpet waste piece along the first machinedirection, the conveyor is reversed and the carpet waste piece is urgedin a second machine direction, opposite to the first machine direction.When the carpet waste piece passes under and proximate the secondrotating shearer, the second rotating shearer is lowered into operativecontact with the exposed material of the carpet waist piece(concurrently, the first rotating shearer is raised up and away fromcontact with the carpet piece). As the middle portion, or a desiredportion, of the carpet piece passes under and proximate to the firstrotating shearer, the first rotating shearer is lowered into operativecontact with the exposed material of the carpet waist piece(concurrently, the second rotating shearer is raised up and away fromcontact with the carpet piece). The carpet piece is repeatedly movedbiaxially under the pair of spaced rotating shearers until the desireddegree of material is removed from the face of the carpet piece.Subsequently, the carpet piece can be flipped over on the conveyor andthe process can be repeated to remove the desired degree of materialsfrom the exposed face of the carpet piece.

In one aspect, it is contemplated that the first and second rotatingshearers can be mounted on opposite ends of an elongated armature. Inthis aspect, it is contemplated that the armature can be configured in ateeter-totter configuration to be selectively rotated about an axistransverse to the machine direction to affect the desired operativeengagement of the respective first and second rotating shearers.

The carpet waste size sensing subsystem 60 of the component wasteseparation system 40 can comprise at least one of a computer visionsystem, a sensor array, or a mechanical fingers (or heddles) to detectthe width of each flattened carpet waste piece. The carpet waste sizesensing subsystem 60 is in communication with the computer controlsystem 80 to provide immediate and real-time system adjustments to therespective components of the component waste separation system 40 forthe optimized downstream abrasion and waste stream separation. In oneaspect, it is contemplated, based on input signals from the carpet wastesize sensing subsystem 60, that the computer control system 80 cansignal the means for selectively moving the shear subsystem, i.e.,selectively signaling and adjusting pneumatic or hydraulic pressure ofthe shear subsystem to maintain a PSI force set-point in order to assuremaximum quality, throughput and consistency.

The backing thickness sensing subsystem 65 of the component wasteseparation system 40 can comprise means for automatically detecting thethickness of the backing material of the carpet waste piece. Referringto FIG. 11, means for automatically detecting the thickness of thebacking material of the carpet waste piece can comprise at least onebacking thickness sensor 67, as exemplarily illustrated. In one example,as shown in option A, the backing thickness sensor comprises a scallopeddisk that is configured to roll across the face of the carpet, pressingits scalloped edge between the tufts of the carpet to establish wherethe backing top is in z-axis space. In another example, as shown inoption B, the backing thickness sensor comprises a sharp roller, akin toa pizza cutter, which is configured to roll across the face of thecarpet, pressing its sharp edge between the tufts of the carpet toestablish where the backing top is in z-axis space. In another exemplaryaspect, as shown in option C, the backing thickness sensor comprises apinned wheel that is configured to roll across the face of the carpet,pressing its pins between the tufts of the carpet to establish where thebacking top is in z-axis space. In another aspect of the backingthickness sensing subsystem 65, the backing thickness sensor 67 can beis mounted on a set of linear bearings or slides that is connected to adistance sensing mechanism, such as, for example and without limitation,a LVDT (Linear Velocity Displacement Transducer), a laser distancesensor, and the like. The distance signal, i.e., the backing thicknesssignal, is sent to the computer control system 80 for conversion andinsertion into the process optimization calculations. It is contemplatedthat other sensing mechanisms can also be employed for the means forautomatically detecting the thickness of the backing material of thecarpet waste piece.

The tuft height and tuft density sensing subsystem 70 of the componentwaste separation system 40 can comprise means for automaticallymonitoring both tuft density and tuft height of the carpet waste piece.In one aspect, the means for automatically monitoring both tuft densityand tuft height of the carpet waste piece can comprise monitoring adisplacement distance in the z-axis substantially transverse to themachine direction of a wide width roller 72. In this aspect, and asshown in FIG. 10, a wide width roller 72 rolls on the top surface, i.e.,the face material surface, of the carpet waste piece as it flows throughthe component waste separation system 40 in the machine direction. Theroller is configured to moves up or down relative to the flat surface ofthe carpet waste piece depending on the relative tuft height or densityof the respective carpet waste piece. In another aspect of the tuftheight and tuft density sensing subsystem 70, the wide width roller 72can be is mounted on a set of linear bearings or slides that isconnected to a distance sensing mechanism, such as, for example andwithout limitation, a LVDT (Linear Velocity Displacement Transducer), alaser distance sensor, and the like. In a further aspect of the tuftheight and tuft density sensing subsystem 70 can comprise at least oneweight, such as, for example and without limitation, a 101 b weight,that is configured to move in the z-axis into operative contact with theface of the carpet waste piece. In this configuration, the weight can beis mounted on a set of linear bearings or slides that is connected to adistance sensing mechanism, such as, for example and without limitation,a LVDT (Linear Velocity Displacement Transducer), a laser distancesensor, and the like.

The displacement distance signal, i.e., the tuft height and tuft densitysignal, is sent to the computer control system 80 for conversion andinsertion into the process optimization calculations. It is contemplatedthat other sensing mechanisms can also be employed for the means forautomatically monitoring both tuft density and tuft height of the carpetwaste piece. It is contemplated that the respective backing thicknesssensing subsystem 65 and the tuft height and tuft density sensingsubsystem 70 allow for the immediate and real time adjustments of thecomponent waste separation system 40 that are necessary for thedownstream abrasion and separation process.

In one aspect, the waste stream output monitoring subsystem 75 of thecomponent waste separation system 40 is coupled to the computer controlsystem 80 and comprises means for monitoring the quantity output offines and mixed fiber produced in the component waste separation system.The waste stream output monitoring subsystem 75 of the component wasteseparation system 40 can also comprise means for adjusting at least oneof: the throughput speed of the component waste separation system 40,the speed of each of the respective shear subsystems, and the force orpressure applied by each of the respective shear subsystems thereon thecarpet waste piece. The means for monitoring the quantity output offines and mixed fiber produced in the component waste separation systemcan comprise conventional optical, ultrasonic, flow or gravimetricmethods to monitor output during the process of shear or otherwiseseparating the backing material from the primary backing of the carpetwaste piece. Based on the overall flow of material through the componentwaste separation system 40, the force or pressure applied by each of therespective shear subsystems thereon the carpet waste piece or engagementdistance can be adjusted as desired. For example and without limitation,this adjustment can be also based on the rotational amperage beingapplied to the respective shear subsystems, which is related to agradual loss of the effective level or degree of abrasiveness of theshear surfaces of the shear subsystems over time.

As one will appreciate from the discussion above, it is contemplatedthat several variables are being sensed real time in component wasteseparation system 40. These parameters being sensed, as data inputs, cancomprise at least one of: backing thickness, pile height, pile density,incoming carpet waste material flat piece width, and shear subsystemrotational motor load. Using this input data, the computer controlsystem 80 can selectively adjust the relative position of the respectiveshear subsystem to a determined engagement distance calculated by thecomputer control system 80 for optimal processing conditions.

In another aspect, after deconstruction of the carpet waste piece in thecomponent waste separation system 40, each material waste stream goesthrough its own system to be further cleaned, separated and opened.Optionally, the face fabric waste stream can be mixed with the primarybacking waste stream for subsequent processing to reduce capitalexpenditures. Typically, after the various carpet components have beenseparated, each respective waste stream requires additional processingin order to become usable material. Referring now to FIG. 1, exemplaryprocessing of the respective waste streams as shown.

In one example, the separated face material or fiber waste stream isurged to a conventional condenser via a conventional blower system, forexample, a vacuum conveyor system. The condenser is configured to removeunwanted dust and particulate matter in preparation for subsequentdelivery to a conventional step cleaner. The step cleaner is configuredto remove unwanted dust and particulate matter, such as, for example andwithout limitation, dirt, calcium carbonate, and the like, from the facematerial or fiber waste stream. After the step cleaner, the facematerial or fiber waste stream can be delivered to another conventionalblower/condenser for final cleansing or removal of unwanted dust andparticulate matter. Finally, the cleansed face material or fiber wastestream can be delivered to a baling station for baling. In this example,the separated unwanted dust and particulate matter is delivered to a baghouse/waste facility.

In one example, the separated backing material waste stream, comprisingbacking material having some degree of face fiber, is delivered to aconventional cyclone separator to separate any fines from the backingmaterial having some degree of face fiber. The separated fines aredelivered downstream to the bag house/waste facility and the separatedbacking material having some degree of face fiber waste stream isdelivered to a downstream size reduction apparatus configured to tearthe waste stream material into fibrous lengths. This size reduction canoptionally be repeated in a secondary downstream size reductionapparatus in preparation for subsequent delivery to a conventional stepcleaner. The step cleaner is configured to remove unwanted dust andparticulate matter, such as, for example and without limitation, dirt,calcium carbonate, and the like, from the backing material having somedegree of face fiber waste stream. After the step cleaner, the cleansedbacking material having some degree of face fiber waste stream isdelivered to a conventional cutter configured chop or reduce the fibrousmaterials to a desired length. After the cutter, the backing materialhaving some degree of face fiber waste stream is urged to a conventionalcondenser configured to remove unwanted dust and particulate matter inpreparation for sequential delivery to a conventional fine opener andstep cleaner. The respective fine opener and step cleaner is configuredto remove unwanted dust and particulate matter, such as, for example andwithout limitation, dirt, calcium carbonate, and the like, from thebacking material having some degree of face fiber waste stream. Finally,the cleansed backing material having some degree of face fiber wastestream can be delivered to a baling station for baling. As in theprevious example, the separated unwanted dust and particulate matter isdelivered to a bag house/waste facility.

In one example, the separated primary backing material waste stream isdelivered to a downstream size reduction apparatus via a conventionalconveyor system that configured to configured to meter and control thesupply of the primary backing material waste stream to the downstreamsize reduction apparatus. In one aspect, the downstream size reductionapparatus is configured to tear the waste stream material into fibrouslengths. This size reduction can optionally be repeated in a secondarydownstream size reduction apparatus in preparation for subsequentdelivery to a conventional step cleaner. The step cleaner is configuredto remove unwanted dust and particulate matter, such as, for example andwithout limitation, dirt, calcium carbonate, and the like, from theprimary backing material waste stream. After the step cleaner, thecleansed primary backing material waste stream is delivered to aconventional cutter configured chop or reduce the fibrous materials to adesired length. After the cutter, the primary backing material wastestream is urged to a conventional condenser configured to removeunwanted dust and particulate matter in preparation for sequentialdelivery to a conventional fine opener and step cleaner. The respectivefine opener and step cleaner is configured to remove unwanted dust andparticulate matter, such as, for example and without limitation, dirt,calcium carbonate, and the like, from the primary backing material wastestream. Finally, the cleansed primary backing material waste stream canbe delivered to a baling station for baling. As in the previousexamples, the separated unwanted dust and particulate matter isdelivered to a bag house/waste facility.

Without limitation the conventional cleaning equipment described abovecan be purchased from Dell Orco & Villani Sri, Vecoplan, Wilson Knowlesand Sons Ltd, Southern Mechatronics, Signal Machine Company Inc, KiceIndustries Inc, Sterling Systems Inc, Pallmann GmbH, OMMI SpA, PierretIndustries Sprl, eFactor 3 LLC, Tria SpA, Weima America Inc, SSIShredding Systems Inc, Erko-Trützschler GmbH, LaRoche SA, Margasa SL,Schirp, Chiavazza Vergnasco, Timtex GmbH, and others. Conventionalcleaning equipment can comprise, without limitation, step cleaners,willows, cyclone separators, vertical vibrating chutes, horizontalvibratory screeners, multi-aspirators, rotary sifters, condensers,guillotine and rotary cutters, fine opening, tearing and other methodsof cleaning.

Although several embodiments of the invention have been disclosed in theforegoing specification, it is understood by those skilled in the artthat many modifications and other embodiments of the invention will cometo mind to which the invention pertains, having the benefit of theteaching presented in the foregoing description and associated drawings.It is therefore understood that the invention is not limited to thespecific embodiments disclosed herein, and that many modifications andother embodiments of the invention are intended to be included withinthe scope of the invention. Moreover, although specific terms areemployed herein, they are used only in a generic and descriptive sense,and not for the purposes of limiting the described invention.

What is claimed is:
 1. A method of reclaiming secondary backingmaterials, primary backing materials, and face materials, from carpetwaste pieces, comprising: removing wrinkles from the carpet wastepieces; and selectively feeding the carpet waste pieces into a componentwaste separation system comprising: a plurality of shear subsystemscomprising a first shear subsystem and a second shear subsystem, whereinthe first shear subsystem is configured to contact the incoming carpetwaste pieces to separate the secondary backing materials from theprimary backing materials of the carpet waste pieces, and wherein thesecond shear subsystem is configured to contact the incoming carpetwaste pieces to separate the face materials from the primary backingmaterials of the carpet waste pieces; wherein the wrinkles are removedfrom the carpet waste pieces at a location upstream of the componentwaste separation system relative to a machine direction of at least thecomponent waste separation system.
 2. The method of claim 1, wherein thecarpet waste pieces are selectively fed through an infeed conveyorsystem.
 3. The method of claim 2, further comprising selectivelyapplying a desired pressure transverse to the machine direction to thecarpet waste pieces passing through the infeed conveyor system.
 4. Themethod of claim 2, further comprising selectively indexing flattenedcarpet waste pieces through the component waste separation system. 5.The method of claim 4, further comprising nipping the carpet wastepieces as they are moved downstream in the machine direction to effectthe desired control of the orientation and metering of the carpet wastematerials at a specified rate.
 6. The method of claim 5, furthercomprising selectively controlling the rate for the carpet wastematerials that are passing through the component waste separationsystem.
 7. The method of claim 5, further comprising selectivelycontrolling a plurality of urging elements to maintain the carpet wastepieces in a desired orientation while moving the carpet waste piecesthrough the plurality of shear subsystems.
 8. The method of claim 7,wherein the plurality of urging elements is selected from a plurality ofbelts and a plurality of pin rollers.
 9. The method of claim 7, whereinthe plurality of urging elements comprises two pluralities of urgingelements, wherein the two pluralities of urging elements are positionedsubstantially parallel to each other and the two pluralities of urgingelements are positioned, at least partially, in opposing, overlappingrelationship to each other.
 10. The method of claim 7, furthercomprising selectively applying pressure transverse to the downstreammachine directional flow to the carpet waste pieces in order to maintaina desired nip and to prevent slippage of the carpet waste pieces. 11.The method of claim 10, further comprising automatically monitoring bothtuft density and tuft height of the carpet waste pieces.
 12. The methodof claim 11, wherein automatically monitoring both tuft density and tuftheight of the carpet waste pieces comprises monitoring a displacementdistance in the z-axis substantially transverse to the machine directionof a wide width roller that rolls over the face materials of the carpetwaste pieces.
 13. The method of claim 11, further comprisingautomatically detecting the thickness of at least the primary backingmaterials of the carpet waste pieces.
 14. The method of claim 13,further comprising selectively adjusting the relative position of therespective shear subsystems relative to the carpet waste pieces to adetermined engagement distance.
 15. The method of claim 7, furthercomprising monitoring a waste stream downstream of the component wasteseparation system relative to the machine direction.
 16. The method ofclaim 1, wherein each of the plurality of shear subsystems is selectedfrom a rotating shearer and a belt-type shearer.
 17. The method of claim16, wherein at least one of the plurality of shear subsystems comprisesa blade shear system that removes a desired portion of the facematerials as the carpet waste pieces are continuously and linearly moveddownstream through the component waste separation system.
 18. The methodof claim 16, wherein the rotating shearer is selected from a continuousrotating shearer or a segmented rotating shearer.
 19. The method ofclaim 18, wherein at least a portion of each rotating shearer has anabrasion surface coupled to at least a portion of an exterior surface ofthe shearer.
 20. The method of claim 1, wherein the carpet waste piecescomprise at least one of: post-consumer carpet, post-consumer processedcarpet; post-industrial carpet, manufacturing remnants, and qualitycontrol carpet failures.